Angled edge connections for multichip structures

ABSTRACT

A multichip module that utilizes an angled interconnect to electrically interconnect chips in the module that are positioned at an angle relative to each other. The multichip module may comprise a first and second chips that are positioned in an orthogonal manner. The first and second chips are electrically interconnected via an interconnect structure comprising a first conductive pillar that extends from an outer surface of the first chip. A distal end of the first pillar is electrically connected to an outer surface of the second chip via a solder ball or another conductive pillar that is interposed between the distal end of the first conductive pillar and the second chip.

RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 09/944,957 filed Aug. 30, 2001. This application is also related toU.S. patent application Ser. No. 10/198,818, filed Jul. 18, 2002,entitled “Angled Edge Connections for Multichip Structures.”

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to multichip structures and, inparticular, to chip interconnections in multichip structures.

2. Description of the Related Art

Semiconductor manufacturers continually strive to increase the packagingdensity of integrated circuit chips, which has led to the development ofhigh density multichip modules, such as three-dimensional multichipstructures. Multichip structures generally comprise a plurality ofintegrated circuit chips that are adhered together in a stack formationso as to reduce the amount of space that the chips occupy inside asystem. It is generally understood that each chip in the stack typicallyhas a plurality of conductive input/output (I/O) contacts that areexposed on a lateral surface of at least one edge of the chip. Theexposed contacts provide a plurality of conductive I/O interconnects forwire bonding the device to external chips and circuitry.

As a result of the increased device density of VLSI (Very-Large-ScaleIntegration) and ULSI (Ultra-Large-Scale Integration) integratedcircuitry, wiring conductive interconnects between input/output (I.O.)terminals of stacked integrated circuit chips has become increasinglymore complex. The limitations brought about by the finite quantity ofavailable space on the surface of a multichip structure and the levelsof conductive traces that are required to wire complex integratedcircuitry, such as microprocessors, memory modules, etc., has limitedthe interconnectivity between chips in multichip structures that requirehigh-density conductive I/O interconnects.

One method of interconnecting chips within multichip structures isthrough the use of the generally known process of wire bonding. The I/Ointerconnection process of wire bonding often requires the formation ofbondable wire bonding pads, which provide electrical contacts to I/Ovias in the insulation layer of an integrated circuit chip.Unfortunately, bondable wire bonding pads may be relatively large. Inaddition, the available space on a substrate surface for surfacemounting conductive I/O interconnects is limited by the finitedimensions of the device. As a result, the disadvantage to wire bondingas a method of I/O interconnection between integrated circuit chips isthat the bonding pads consume a large amount of the available space onthe integrated circuit chip surface. Therefore, the fabrication densityis limited by the dimensions of the wire bonding pad and further by thefinite dimensions of the integrated circuit chip surface. To furtherincrease the fabrication density of integrated circuitry, amanufacturing process that reduces the need for wire bonding as a meansfor establishing a conductive link between I/O interconnects would bepreferred.

In another aspect, integrated circuits chips within a multichipstructure may be interconnected by a direct solderable C4 connection,but the I/O interconnection surfaces are usually limited to an opposedparallel positioning of the integrated circuit chips. An opposingparallel position refers to a chip configuration where the bondingelements are interposed between two parallel bonding plane surfaces oftwo opposing chips, which is similar to a sandwich configuration.Disadvantageously, the opposing parallel configuration reducesinterconnection and mounting flexibility and can only be applied toparallel oriented chips in multichip structures, which is likely toreduce the available I/O interconnect density for chips that are notparallel and adjacent to one another.

Hence, it will be appreciated that there is a need for a method ofincreasing the interconnect density and interconnection flexibilitybetween chips in multichip modules. There is also a need for a method ofelectrically connecting chips that are not positioned in an opposingparallel fashion. To this end, there is a particular need for amultichip structure that provides an increased interconnect density andflexibility between chips that are not positioned parallel to oneanother.

SUMMARY OF THE INVENTION

In one aspect, the preferred embodiments of the present inventiondisclose an integrated circuit module comprising a first semiconductorstructure having a first surface defined by a first plane and a secondsemiconductor structure having a second surface defined by a secondplane, wherein the second structure is positioned adjacent the firststructure in a manner such that the second plane intersects the firstplane. The module further comprises a first connecting member extendingfrom the first surface of first structure. Preferably, the firstconnecting member has a first distal end that is electrically connectedto the first surface and a second distal end extending from the firstsurface along a first axis.

Preferably, the module also comprises a second connecting member that isinterposed between the second distal end of the first connecting memberand the second surface of the second structure, wherein the secondconnecting member electrically interconnects the second distal end tothe second surface and forms a bond therebetween along a second axis.Preferably, the second axis is not parallel to the first axis. In oneembodiment, the first connecting member comprises a conductive pillarand the second connecting member comprises a solder ball. In anotherembodiment, both the first and second connecting members compriseconductive pillars and the conductive pillars may be joined together viasolder.

In another aspect, the preferred embodiments of the present inventiondisclose a multichip module comprising a plurality of semiconductorchips stacked and secured together to form a base structure wherein thebase structure has a first and a second lateral face, wherein eachlateral face is comprised of a portion of each chip, wherein the firstlateral face is adjacent to and substantially perpendicular to thesecond lateral face. The module further comprises a first exteriorsemiconductor chip mounted to the first lateral face of the basestructure in a manner such that a first surface of the first exteriorchip is positioned adjacent to the first lateral face and extends acrossat least a portion of the first lateral face. Preferably, the modulealso comprises a second exterior semiconductor chip mounted to thesecond lateral face of the base structure in a manner such that a firstsurface of the second exterior chip is positioned adjacent to the secondlateral face and extends across at least a portion of the second lateralface. The first and second exterior chips are electrically connected viaa connecting member. Preferably, the connecting member comprises a firstdistal end that is electrically connected to the first surface of thefirst exterior chip and a second distal end that is electricallyconnected to the first surface of the second exterior chip. In oneembodiment, the connecting member comprises a conductive pillar. Asolder ball is preferably interposed between the second distal end ofthe connecting member and the first surface of the second semiconductorchip. In another embodiment, the first distal end of the connectingmember extends along a first axis and the second distal end extendsalong a second axis, wherein the first axis and the second axis arenon-parallel.

In yet another aspect, the preferred embodiments of the presentinvention is directed to a method of forming electrical interconnectionsbetween two integrate circuit structures. The method comprises forming afirst conductive contact on a first surface of a first semiconductorchip and a second conductive contact on a second surface of a secondsemiconductor chip. The method further comprises forming a connectingmember on the first contact wherein a distal end of the connectingmember extends from the first surface of the first semiconductor chip.The method further comprises positioning the chips in a manner such thatthe plane defining the first surface intersects with plane the definingthe second surface. Furthermore, the method comprises affixing thedistal end of the connecting member to the second contact of the secondchip to electrically connect the first and second semiconductor chips.In one embodiment, the distal end can be affixed to the second contactby interposing either a solder ball or a conductive pillar between thedistal end and the second contact. In another embodiment, the conductivepillar can be formed by a selective CVD, electroless plating,electroplating, or a blanket deposition using a tape lift-off process.In yet another embodiment, the solder ball can be formed via a selectiveimmersion, tape lift-off, or metal mask process and then reflowed in H₂.

Advantageously, the preferred embodiments of the present inventionprovide an increased interconnection flexibility between integratedcircuit chips. In particular, densely packed multichip structures may bemounted and interconnected at an angular offset from each other, whichalso allows for a reduction of unused space within the structure and anadaptation to irregular shaped configurations. With increasedinterconnection flexibility, multichip structures may utilize a greaterarea of surface space for multichip interconnectivity and thus increasethe interconnect density. The increased interconnect flexibility anddensity may result in an increase in speed of the multichip structuredue to the increase in available I/O interconnections and a reducedconductive trace length between multiple chip I/O interconnections.These and other advantages of the present invention will become morefully apparent from the following description taken in conjunction withthe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides a schematic illustration of a multichip structure of thepreferred embodiment, showing the chips positioned at a substantiallyorthogonal angle and interconnected using the preferred interconnectionmethod;

FIG. 2 provides a schematic illustration of another preferred embodimentof a multichip structure, showing the chips positioned at an acute angleand interconnected using the preferred interconnection method;

FIG. 3 provides a schematic illustration of another embodiment of themultichip structure of FIG. 1, showing another embodiment of theinterconnection method;

FIG. 4 illustrates a schematic illustration of yet another embodiment ofa multichip structure, showing three chips interconnected to each otherusing one embodiment of the preferred interconnection method;

FIG. 5 illustrates a schematic illustration of one embodiment of athree-dimensional multichip module utilizing one embodiment of thepreferred interconnection method;

FIG. 6 illustrates a cross-sectional view of the three-dimensionalmultichip module in FIG. 5 taken along line 6—6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

References will now be made to the drawings wherein like numerals referto like parts throughout. FIG. 1 illustrates a multichip structure 110of a preferred embodiment. The multichip structure 110 comprises a firstintegrated circuit chip 111 having a first surface 116 a and a secondintegrated circuit chip 112 having a second surface 116 b. As shown inFIG. 1, the chips 111, 112 are positioned in a manner such that thefirst surface 116 a is substantially adjacent and orthogonal to thesecond surface 116 b. As FIG. 1 further shows, a first conductivecontact 115 a is formed on the first chip 111 and a first connectingmember 113 extends from the first contact 15 a. Preferably, a secondconductive contact 115 b is also formed on the second chip 112 and asecond connecting member 114 is interposed between the first connectingmember 113 and the second contact 115 b so as to establish electricalinterconnection therebetween. Particularly, the first connecting member113 has a first distal end 118 a that is attached to the first contact115 a and a second distal end 118 b that extends from the first surface116 a along a first axis. The second connecting member 114 is preferablyinterposed between the second distal end 118 b and the second contact115 b so as to form a conductive bond therebetween. Preferably, the bondis formed along a second axis that is not parallel to the first axis.

In one embodiment, the first connecting member 113 is a conductivepillar comprising a conductive material, such as copper, while thesecond connecting member 114 may be a generally known solder ball usedin C4 interconnections. In one embodiment, the solder ball 114 may befirst formed on the second distal end 118 b of the first connectingmember 113 and then bonded to the second contact 115 b on the secondsurface 116 b. In another embodiment, the solder ball 114 may be firstformed on the second contact 115 b and then bonded to the second distalend 118 b of the first connecting member 113. The advantage to using theconductive pillar 113 in conjunction with the solder ball 114 is that anangular conductive interconnection may be established between twosemiconductor structures, such as the first and second chips 111, 112.Therefore, conductive interconnection between chips is not limited tochips positioned in an opposing parallel position.

As shown in FIG. 1, the first and second connecting members 113, 114 arejoined together to electrically interconnect the chips 111, 112. In oneembodiment, the first and second chips 111, 112 may comprise electricaldevices such as logic gates, memory modules, capacitors, resistors, andthe like. In another embodiment, the first and second chips 111, 112 maybe replaced with insulator based wafers comprising a plurality ofconductive traces for interconnection of electrical components betweenintegrated circuit chips.

A preferred process for the fabrication of the multichip structure 110shown in FIG. 1 may proceed as follows. The first and second chips 111,112 are fabricated in accordance with conventional integrated circuitmanufacturing processes. After the completion of the next to last layerof chip metallurgy, an insulating layer is deposited on the first andsecond chips 111, 112 and planarized using methods that are known in theart. A solderable metallurgy layer is then deposited on the insulatinglayer and photo processed to form the last level of conductive tracesand/or conductive contact points. Preferably, the conductive contactpoints comprise the first and second conductive contacts 115 a, 115 b asshown in FIG. 1. In one embodiment, the contacts 115 a, 115 b compriseconductive pads that provide electrical interconnection to internalcircuitry in the chips. Subsequent to forming the conductive contacts115 a, 115 b, the conductive pillar 113 may be formed on the firstcontact 115 a using selective CVD, electroless plating, electroplatingor a blanket deposition in conjunction with a known tape life-offprocess. Similarly, the solder ball 114 may be formed on the secondexposed contact 115 b using generally known C4 (Controlled CollapsedChip Connection) processes, in which a lift-off procedure is used toform the solder ball. Alternatively, the solder ball 114 may be formedon the second distal end 118 b of the first connecting member 113 usingseveral different known methods such as selective immersion, tapelift-off, or metal mask to deposit solder. In one embodiment, theprocess continues by reflowing the solder in H₂ to form a solder ball114. The multichip module 110 may be subsequently mounted to anappropriate substrate, which may be the outer surface of a multichipstacked module as will be discussed further below.

FIG. 2 illustrates another embodiment of a multichip structure 210showing a second chip 212 positioned at an angular offset 217 from afirst chip 211. In this embodiment, the angle 217 formed between the twochips 211, 212 is less than 90 degrees, however, it can be appreciatedthat this angle can vary without departing from the scope of theinvention. In another embodiment, for example, the angle 217 may begreater than 90 degrees. As shown in FIG. 2, a conductiveinterconnection 221 between the two chips 211, 212 is achieved in asimilar manner as the interconnection 121 illustrated in FIG. 1. Similarto the module illustrated in FIG. 1, the conductive interconnection 221comprises a first connecting member 213 which extends from a firstcontact 215 a formed on the first chip. A second connecting member 214,which preferably comprises a solder ball, is interposed between thefirst connecting member and a second contact 215 b formed on the secondchip 212. As illustrated in FIG. 2, if it is desired to attach the chips211, 212 at an angular offset other than orthogonal as in FIG. 1, thesame procedures may be used as in FIG. 1 except that the chips would bepositioned at the desired angle prior to attaching the first connectingmember to the second connecting member. These connections are especiallyuseful in complex multichip stack modules, which will be discussed infurther detail below. It should also be apparent to one skilled in theart that these connections can be adapted to structures using generallyknown C4 connections so that the contact between the chips may besecured at various angles.

FIG. 3 illustrates yet another embodiment of a multichip structure 310.In this embodiment, the multichip structure 310 comprises a secondconnecting member 313 b that is also a conductive pillar having a firstdistal end 319 a and a second distal end 319 b. The first distal end 319a is attached to a second exposed contact 315 b formed a second surface316 b of the second chip 312. Preferably, the second distal end 319 bextends from the second surface 316 b along an axis that issubstantially orthogonal to the first connecting member 313 a. Thesecond distal end 319 b of the second connecting member 313 b ispositioned adjacent to the second distal end 318 b of the firstconnecting member 313 a. Furthermore, a conductive bonding element 320such as solder is used to electrically interconnect the second distalends 318 b, 319 b of the connecting members 313 a, 313 b. The advantageto this particular embodiment is increased orientation flexibility,where the positioning of the first and second chips 311, 312 may formvarious angular displacements between the two chips 311, 312 withoutdeparting from the scope of the invention.

FIG. 4 illustrates still another embodiment of a multichip structure410. The multichip structure 410 further includes a third chip 423. Thethird chip 423 is positioned substantially parallel to the second chip412 and interconnected to the second chip 412 by way of a plurality ofconductive interconnects 425. In one embodiment, the conductiveinterconnects 425 comprise conventional C4 solder connections. Thisparticular embodiment illustrates the angular mounting of chips 411, 412substantially orthogonal to each other via the conductiveinterconnection 421 described above and the simultaneous mounting ofchips 412, 423 substantially parallel to each other via the conductiveinterconnection 425. The advantage to multiple chip mountingorientations is that chip interconnection density may be increased dueto an increase in the chip mounting flexibility between chips 411, 412,423. The advantage to this chip mounting configuration is that aplurality of planar structures may be simultaneously mounted in bothangular and parallel configurations in one multichip structure.

FIG. 5 illustrates one embodiment of a three-dimensional multichipmodule 550, which utilizes the interconnection methods described aboveto interconnect the exterior chips of the module. As FIG. 5 shows, themultichip module 550 comprises a plurality of semiconductor chips 520stacked and secured together to form a base structure 525, wherein thebase structure has four lateral faces 530 a-d (only one is shown).Preferably, each lateral face 530 is comprised of a portion of eachchip. Preferably, a first lateral face 530 a is adjacent to andsubstantially perpendicular to a second lateral face 530 b, while athird lateral face 530 c is adjacent to and substantially perpendicularto the second face 530 b. As FIG. 5 shows, a first exteriorsemiconductor chip 562 is mounted to the first lateral face 530 a of thebase structure 525 in a manner such that a first surface (not shown) ofthe first exterior chip 562 is positioned adjacent to the first lateralface 530 a and extends across at least a portion of the first lateralface 530 a. Furthermore, a second exterior semiconductor chip 561 ismounted to the second lateral face 530 b of the base structure 525 in amanner such that a first surface (not shown) of the second exterior chip561 is positioned adjacent to the second lateral face 530 b and extendsacross at least a portion of the second lateral face. Similarly, a thirdexterior chip 560 is mounted to the third lateral face 530 c of the basestructure 525 in a manner such that a first surface (not shown) of thethird exterior chip 560 is positioned adjacent to the third lateral face530 c and extends across at least a portion of the third lateral face530 c. The multichip module 550 is described in detail in Applicant'sco-pending U.S. Patent Application entitled “A THREE-DIMENSIONALMULTICHIP MODULE AND METHOD OF MAKING THE SAME”, which is incorporatedby reference herein in its entirety.

FIG. 6 illustrates a cross-sectional view taken along the line 6—6 ofthe three-dimensional multichip module 550 shown in FIG. 5. FIG. 6 showsthe three exterior chips 560, 561, 562 are interconnected with eachother using conductive interconnects 521, 525, 527 of the preferredembodiments shown and described above in detail in FIGS. 1-4. As shownin FIG. 6, the exterior chips 560, 561, 562 are mounted in parallel withthe exterior faces of the base structure 525 through the plurality ofconductive interconnections 525, 527 and also orthogonal to each otherthrough the conductive interconnections 521. In one embodiment, theexterior chips 560, 561, 562 are aligned, in a manner known in the art,prior to mounting to the base structure 525, and the module 550 is thenheated in an inert or reducing atmosphere to the melting point of thesolder used as connecting members.

The conductive interconnection 521 of the preferred embodiment allowsfor the exterior chips 560, 561, 562 to be interconnected to each otherfor an increased I/O interconnection density, wherein an increase in thespeed of the device is achieved by increasing the number of availableI/O interconnects. Another advantage gained is an increase in theinterconnection flexibility of the multichip structure, whereby anglededge connections offer increased efficiency and performance of themultichip structural system. As such, the above-mentioned fabricationprocess significantly increases the I/O interconnect density and theinterconnect flexibility of multichip stacked structures. A process andstructure that allows solderable connections to be produced with anincreased I/O density and increased I/O interconnect flexibilityimproves the efficiency and the performance of a multichip stackedstructure.

Although the foregoing description of the various embodiments of thepresent invention have shown, described, and pointed out the fundamentalnovel features of the present invention, it will be understood thatvarious omissions, substitutions, and changes in the form of the detailof the apparatus as illustrated as well as the uses thereof, may be madeby those skilled in the art, without departing from the scope of thepresent invention. Consequently, the scope of the present inventionshould not be limited to the foregoing discussions, but should bedefined by the appended claims.

What is claimed is:
 1. An integrated circuit module, comprising: a firstsemiconductor structure having a first surface defined by a first plane;a second semiconductor structure having a second surface defined by asecond plane, wherein the second structure is positioned adjacent thefirst structure in manner such that the second plane intersects thefirst plane; a first connecting member extending from the first surfaceof the first structure, the first connecting member having a firstdistal end electrically connected to the first surface and a seconddistal end extending from the first surface along a first axis; and asecond connecting member interposed between the second distal end of thefirst connecting member and the second surface of the second structure,wherein the second connecting member electrically interconnects thesecond distal end to the second surface and forms a bond therebetweenalong a second axis, wherein the second axis is not parallel to thefirst axis.
 2. The module of claim 1, wherein the second planeintersects the first plane at an approximately 90 degree angle.
 3. Themodule of claim 1, wherein the second plane intersects the first planeat an angle greater than 90 degrees.
 4. The module of claim 1, whereinthe second plane intersects with the first plane at an angle less than90 degrees.
 5. The module of claim 1, wherein the first connectingmember comprises a conductive pillar.
 6. The module of claim 5, whereinthe conductive pillar comprises copper.
 7. The module of claim 5,wherein the second connecting member comprises a solder ball.
 8. Themodule of claim 7, wherein the second connecting member comprises a C4structure.
 9. The module of claim 7, wherein the solder ball is formedon the second surface of the second semiconductor structure and extendsfrom the second surface along the second axis to make contact with thesecond distal end of the first connecting member.
 10. The module ofclaim 7, wherein the solder ball is formed on the second distal end ofthe first connecting member and extends from the second distal end alongthe second axis to make contact with the second surface of the secondsemiconductor structure.
 11. The module of claim 1, further comprising afirst conductive contact formed on the first surface of the firstsemiconductor structure, wherein the first distal end of the firstconnecting member is positioned adjacent to the first conductivecontact.
 12. The module of claim 11, wherein the first conductivecontact comprises a conductive pad.
 13. The module of claim 11, whereinthe first conductive contact comprises a conductive via.
 14. The moduleof claim 1, further comprising a second conductive contact formed on thesecond surface of the second semiconductor structure, wherein the secondconnecting member contacts the second conductive contact.
 15. The moduleof claim 14, wherein the second conductive contact comprises aconductive pad.
 16. The module of claim 15, wherein the secondconductive contact comprises a conductive via.
 17. The module of claim14, wherein the second connecting member comprises a conductive pillarhaving a first distal end positioned adjacent to the second conductivecontact and a second distal end extending from the second surface alongthe second axis.
 18. The module of claim 17, wherein the second distalend of the first connecting member and the second distal end of thesecond connecting member are joined together via a solder joint.
 19. Themodule of claim 18, wherein the first and second connecting members arejoined together at an approximately 90 degree angle.
 20. The module ofclaim 1, wherein the first semiconductor structure comprises anintegrated circuit chip.
 21. The module of claim 20, wherein the secondsemiconductor structure comprises an integrated circuit chip.
 22. Themodule of claim 21, wherein the integrated circuit structure is adaptedto be mounted to a multichip structure comprising a plurality ofintegrated circuit chips secured together in a stack.
 23. The module ofclaim 20, wherein the integrated circuit structure is mounted to a thirdintegrated circuit chip in a manner such that a first surface of thethird chip is positioned adjacent and substantially parallel to thesecond surface of the second chip, wherein the third chip iselectrically connected to the second surface via a plurality of soldercontacts formed between the second and third chips.